Publications

This paper documents an investigation of approaches to improving the quality of Pro/Engineer-created solid model data for use by downstream applications. The investigation identified a number of sources of problems caused by deficiencies in Pro/Engineer`s geometric engine, and developed prototype software capable of detecting many of these problems and guiding users towards simplified, useable models. The prototype software was tested using Sandia production solid models, and provided significant leverage in attacking the simplification problem.

The CONTAIN 2.0 computer code is an integrated analysis tool used for predicting the physical conditions, chemical compositions, and distributions of radiological materials inside a containment building following the release of material from the primary system in a light-water reactor accident. It can also predict the source term to the environment. CONTAIN 2.0 is intended to replace the earlier CONTAIN 1.12, which was released in 1991. The purpose of this Code Manual is to provide full documentation of the features and models in CONTAIN 2.0. Besides complete descriptions of the models, this Code Manual provides a complete description of the input and output from the code. CONTAIN 2.0 is a highly flexible and modular code that can run problems that are either quite simple or highly complex. An important aspect of CONTAIN is that the interactions among thermal-hydraulic phenomena, aerosol behavior, and fission product behavior are taken into account. The code includes atmospheric models for steam/air thermodynamics, intercell flows, condensation/evaporation on structures and aerosols, aerosol behavior, and gas combustion. It also includes models for reactor cavity phenomena such as core-concrete interactions and coolant pool boiling. Heat conduction in structures, fission product decay and transport, radioactive decay heating, and the thermal-hydraulic and fission product decontamination effects of engineered safety features are also modeled. To the extent possible, the best available models for severe accident phenomena have been incorporated into CONTAIN, but it is intrinsic to the nature of accident analysis that significant uncertainty exists regarding numerous phenomena. In those cases, sensitivity studies can be performed with CONTAIN by means of user-specified input parameters. Thus, the code can be viewed as a tool designed to assist the knowledge reactor safety analyst in evaluating the consequences of specific modeling assumptions.

This report provides a summary of the Pulser In a Chip 9000-Discretionary LDRD. The program began in January of 1997 and concluded in September of 1997. The over-arching goal of this LDRD is to study whether laser diode triggered photoconductive semiconductor switches (PCSS) can be used to activate electro-optic devices such as Q-switches and Pockels cells and to study possible laser diode/switch integration. The PCSS switches we used were high gain GaAs switches because they can be triggered with small amounts of laser light. The specific goals of the LDRD were to demonstrate: (1) that small laser diode arrays that are potential candidates for laser-switch integration will indeed trigger the PCSS switch, and (2) that high gain GaAs switches can be used to trigger optical Q-switches in lasers such as the lasers to be used in the X-1 Advanced Radiation Source and the laser used for direct optical initiation (DOI) of explosives. The technology developed with this LDRD is now the prime candidate for triggering the Q switch in the multiple lasers in the laser trigger system of the X-1 Advanced Radiation Source and may be utilized in other accelerators. As part of the LDRD we developed a commercial supplier. To study laser/switch integration we tested triggering the high gain GaAs switches with: edge emitting laser diodes, vertical cavity surface emitting lasers (VCSELs), and transverse junction stripe (TJS) lasers. The first two types of lasers (edge emitting and VCSELs) did activate the PCSS but are harder to integrate with the PCSS for a compact package. The US lasers, while easier to integrate with the switch, did not trigger the PCSS at the US laser power levels we used. The PCSS was used to activate the Q-switch of the compact laser to be used in the X-1 Advanced Radiation Source.

During November/96 to April/97 Sandia National Laboratories provided consulation, data collection, analysis and project documentation to the U.S. Army for a series of four geothermal exploratory slimholes drilled on the McGregor Range approximately 25 miles north of El Paso, Texas. This drilling was directed toward evaluating a potential reservoir for geothermal power generation in this area, with a secondary objective of assessing the potential for direct use applications such as space heating or water de-salinization. This report includes: representative temperature logs from the wells; daily drilling reports; a narrative account of the drilling and testing; a description of equipment used; a summary and preliminary interpretation of the data; and recommendations for future work.

The WCEDS prototype software system was developed to investigate the usefulness of waveform correlation methods for CTBT monitoring. The WCEDS prototype performs global seismic event detection and has been used in numerous experiments. This report documents the software system design, presenting an overview of the system operation, describing the system functions, tracing the information flow through the system, discussing the software structures, and describing the subsystem services and interactions. The effectiveness of the software design in meeting project objectives is considered, as well as opportunities for code refuse and lessons learned from the development process. The report concludes with recommendations for modifications and additions envisioned for regional waveform-correlation-based detector.

This report presents a detailed analysis of the results from fatigue studies of wind turbine blade composite materials carried out at Montana State University (MSU) over the last seven years. It is intended to be used in conjunction with the DOE/MSU composite Materials Fatigue Database. The fatigue testing of composite materials requires the adaptation of standard test methods to the particular composite structure of concern. The stranded fabric E-glass reinforcement used by many blade manufacturers has required the development of several test modifications to obtain valid test data for materials with particular reinforcement details, over the required range of tensile and compressive loadings. Additionally, a novel testing approach to high frequency (100 Hz) testing for high cycle fatigue using minicoupons has been developed and validated. The database for standard coupon tests now includes over 4,100 data points for over 110 materials systems. The report analyzes the database for trends and transitions in static and fatigue behavior with various materials parameters. Parameters explored are reinforcement fabric architecture, fiber content, content of fibers oriented in the load direction, matrix material, and loading parameters (tension, compression, and reversed loading). Significant transitions from good fatigue resistance to poor fatigue resistance are evident in the range of materials currently used in many blades. A preliminary evaluation of knockdowns for selected structural details is also presented. The high frequency database provides a significant set of data for various loading conditions in the longitudinal and transverse directions of unidirectional composites out to 10{sup 8} cycles. The results are expressed in stress and strain based Goodman Diagrams suitable for design. A discussion is provided to guide the user of the database in its application to blade design.

An efficient method is presented for calculation of RMS von Mises stresses from stress component transfer functions and the Fourier representation of random input forces. An efficient implementation of the method calculates the RMS stresses directly from the linear stress and displacement modes. The key relation presented is one suggested in past literature, but does not appear to have been previously exploited in this manner.

This study is the second phase in a combined analytical and experimental effort to characterize and improve the ride quality of the Department of Energy tractor/trailer. The discussion includes a brief overview of the finite element model of the vehicle and experimental road and modal test results. A novel system identification approach is used, employing both lab-based modal tests, and modal data derived using the Natural Excitation Technique (NExT), a scheme that utilizes the roadway surface as a natural forcing function. The use of a cab isolation system is investigated with the computer model for purposes of improving the ride quality of the vehicle. To validate these analytical predictions, an engineering prototype vehicle was developed, which included a cab isolation system, to experimentally assess ride quality. Ride quality improvements due to the addition of the isolation system are then assessed both experimentally and analytically, and the results are compared.

The predictive modeling of vibration of many structural systems is crippled by an inability to predictively model the mechanics of joints. The lack of understanding of joint dynamics is evidenced by the substantial uncertainty of joint compliances in the numerical models and by the complete inability to predict joint damping. The lore is that at low amplitudes, joint mechanics are associated with Coulomb friction and stick-slip phenomena and that at high amplitudes, impact processes result in dissipation as well as shift of energy to other frequencies. Inadequate understanding of the physics precludes reliable predictions. In this introductory work, joint compliance is studied in both a numerical and experimental setting. A simple bolted interface is used as the test article and compliance is measured for the joint in both compression and in tension. This simple interface is shown to exhibit a strong non-linearity near the transition from compression to tension (or vice-versa). Modeling issues pertaining to numerically solving for the compliance are addressed. It is shown that the model predicts the experimental strains and compliance fairly well. It will be seen that the joint behavior is a mechanical analogy to a diode. In compression, the joint is very stiff, acting almost as a rigid link, while in tension the joint is soft, acting as a soft spring. Although there have been many other studies performed on bolted joints, the variety of joint geometries has demonstrated large variations in behavior. This study is an attempt to quantify the behavior of typical joints found in today`s weapon systems.

Cl{sub 2}-based Inductively Coupled Plasmas with low additional dc self- biases(-100V) produce convenient etch rates(500-1500 A /min) for GaN, AlN, InN, InAlN and InGaN. A systematic study of the effects of additive gas(Ar, N{sub 2}, H{sub 2}), discharge composition and ICP source power and chuck power on etch rate and surface morphology has been performed. The general trends are to go through a maximum in etch rate with percent Cl{sub 2} in the discharge for all three mixtures, and to have an increase(decrease) in etch rate with source power(pressure). Since the etching is strongly ion-assisted, anisotropic pattern transfer is readily achieved. Maximum etch selectivities of approximately 6 for InN over the other nitrides were obtained.

This paper describes a modular approach for computing redundant robot kinematics. First some conventional redundant control methods are presented and shown to be `passive control laws`, i.e. they can be represented by a network consisting of passive elements. These networks are then put into modular form by applying scattering operator techniques. Additional subnetwork modules can then be added to further shape the motion. Modules for obstacle detection, joint limit avoidance, proximity sensing, and for imposing nonlinear velocity constraints are presented. The resulting redundant robot control system is modular, flexible and robust.

This paper describes a modeling technique for single-agent reactive systems, that is influenced by the modeling paradigm of Parnas as well as by the synchronous paradigms of LUSTRE and ESTEREL. In this paradigm, single-agent reactive systems are modeled in a universe having a discrete clock. This discretization of time greatly reduces the temporal complexity of the model. According to the author, the advantage of this reduction in temporal complexity is that the resulting model is in many ways better suited to automated software construction and analysis techniques (e.g., deductive synthesis, transformation, and verification) than models that are based on continuous representations of time.

Effective management of DOE`s transportation operations requires better data than are currently available, a more integrated management structure for making transportation decisions, and decision support tools to provide needed analysis capabilities. This paper describes a vision of an advanced logistics management system for DOE, and the rationale for developing improved modeling and simulation capability as an integral part of that system. The authors illustrate useful types of models through four examples, addressing issues of transportation package allocation, fleet sizing, routing/scheduling, and emergency responder location. The overall vision for the advanced logistics management system, and the specific examples of potential capabilities, provide the basis for a conclusion that such a system would meet a critical DOE need in the area of radioactive material and waste transportation.

Sandia was presented with an opportunity in 1993 to design containers for the long term storage and transport of fissile material. This program was undertaken at the direction of the US Department of Energy and in cooperation with Lawrence Livermore National Laboratory and Los Alamos National Laboratory which were tasked with developing the internal fixturing for the contents. The hardware is being supplied by Allied Signal Federal Manufacturing and Technologies, and the packaging will occur at Mason and Hangar Corporation`s Pantex Plant. The unique challenge was to design a container that could be sealed with the fissile material contents; and, anytime during the next 50 years, the container could be transported with only the need for the pre-shipment leak test. This required not only a rigorous design capable of meeting the long term storage and transportation requirements, but also resulted in development of a surveillance program to ensure that the container continues to perform as designed over the 50-year life. This paper addresses the design of the container, the testing that was undertaken to demonstrate compliance with US radioactive materials transport regulations, and the surveillance program that has been initiated to ensure the 50-year performance.

The authors propose a general technique called solution decomposition to devise approximation algorithms with provable performance guarantees. The technique is applicable to a large class of combinatorial optimization problems that can be formulated as integer linear programs. Two key ingredients of the technique involve finding a decomposition of a fractional solution into a convex combination of feasible integral solutions and devising generic approximation algorithms based on calls to such decompositions as oracles. The technique is closely related to randomized rounding. The method yields as corollaries unified solutions to a number of well studied problems and it provides the first approximation algorithms with provable guarantees for a number of new problems. The particular results obtained in this paper include the following: (1) The authors demonstrate how the technique can be used to provide more understanding of previous results and new algorithms for classical problems such as Multicriteria Spanning Trees, and Suitcase Packing. (2) They show how the ideas can be extended to apply to multicriteria optimization problems, in which they wish to minimize a certain objective function subject to one or more budget constraints. As corollaries they obtain first non-trivial multicriteria approximation algorithms for problems including the k-Hurdle and the Network Inhibition problems.

The Waste Isolation Pilot Plant (WIPP) Compliance Certification Application (CCA) Performance Assessment (PA) used a relational database that was originally designed only to supply the input parameters required for implementation of the PA codes. Reviewers used the database as a point of entry to audit quality assurance measures for control, traceability, and retrievability of input information used for analysis, and output/work products. During these audits it became apparent that modifications to the architecture and scope of the database would benefit the EPA regulator and other stakeholders when reviewing the recertification application. This paper contains a discussion of the WPP PA CCA database and lessons learned for designing a database.

When implementing a Quality Assurance (QA) program, compliance and cost must be balanced. A QA program must be developed that hits the mark in terms of adequate control and documentation, but does not unnecessarily expand resources. As the Waste Isolation Pilot Plant (WIPP) has moved towards certification, Sandia National Laboratories has learned much about balancing compliance and costs. Some of these lessons are summarized here.

The Yucca Mountain Project conducted a Single Heater Test (SHT) in the Exploratory Studies Facility at Yucca Mountain. During the nine month-long heating phase, approximately 4 m{sup 3} of in situ, fractured, 92% saturated, welded tuff was heated to temperatures above 100 C by a 5 m long, 3.8 kW, horizontal, line heater. In this paper, the thermal data collected during the test (Sandia National Laboratories, 1997) are compared to three numerical simulations (Sobolik et al., 1996) in order to gain insight into the coupled thermal-hydrologic processes. All three numerical simulations rely on the Equivalent Continuum Model (ECM) for reasons of computational efficiency. The ECM assumes that the matrix and the fractures are in thermodynamic equilibrium which allows the thermal and hydrologic properties of the matrix and the fractures to be combined into single, bulk values. The three numerical simulations differ only in their bulk permeabilities and are referred to as the High, Low and Matrix Permeability Models, respectively. In the Matrix Permeability Model, the system behaves as an unfractured porous medium with the properties of the rock matrix.

Movement of water through fractures plays an important role in performance assessments of the potential high-level nuclear waste repository at Yucca Mountain, Nevada. The magnitude and frequency of water flowing through individual fractures impacts predictions of the near-field environment and waste-package corrosion. Discrete fracture flow paths, referred to as ``weeps``, have been derived from dual continuum models of fracture flow. The required parameters include the geometric fracture spacing, an assumed width of each weep, and a scaling factor that accounts for reduced flow between fracture and matrix elements in dual continuum models. The formulation provides a convenient means to determine discrete weep spacing and flow rates that are mathematically consistent with the dual continuum model. Specific applications and examples related to seepage into drifts are also discussed.

This paper presents simulations of unsaturated groundwater flow and radionuclide transport at Yucca Mountain using the numerical codes TOUGH2 and FEHM. The simulations test the proposed methodology for coupling flow and transport in the upcoming Total Systems Performance Assessment and Viability Assessment (TSPA-VA). The simulations also reveal the sensitivity of transport results to different weighting schemes for hydraulic conductivities used in liquid flux calculations. Results indicate that coupling TOUGH2 and FEHM is a viable method for simulating flow and transport at Yucca Mountain when a modified upstream weighting scheme is used to simulate the flow fields.

The Russian-US joint program on the safety of nuclear materials was initiated in response to the 1993 Tomsk-7 accident. The bases for this program are the common technical issues confronting the US and Russia in the safe management of excess weapons grade nuclear materials. The US and Russian weapons dismantlement process is producing hundreds of tons of excess Pu and HEU fissile materials. The US is on a two path approach for disposition of excess Pu: (1) use Pu in existing reactors and/or (2) immobilize Pu in glass or ceramics followed by geologic disposal. Russian plans are to fuel reactors with excess Pu. US and Russia are both converting and blending HEU into LEU for use in existing reactors. Fissile nuclear materials storage, handling, processing, and transportation will be occurring in both countries for tens of years. A table provides a history of the major events comprising the Russian-US joint program on the safety of nuclear materials. A paper delineating program efforts was delivered at the SPECTRUM '96 conference. This paper provides an update on program activities since then.

Direct metal deposition technologies produce complex, near net shape components from CAD solid models. Most of these techniques fabricate a component by melting powder in a laser weld pool, rastering this weld bead to form a layer, and additively constructing subsequent layers. Powder feed material in these processes results in near net shape, high strength components, with the ability to blend materials for novel properties. This talk will describe a new direct metal deposition process, known as 3DWire, whereby a small diameter wire is used instead of powder as the feed material to fabricate components. This allows for faster deposition rates, smoother surface finishes, and easy material handling. Currently, parts are being fabricated from 308L stainless steel and Aermet{reg_sign} 100. Microscopy studies show the 3DWire parts to be fully dense with fine microstructural features. Initial mechanical tests show stainless steel parts to have good strength values ({sigma}{sub y} = 58 ksi, {sigma}{sub ult} = 95 ksi, 87 HRB) with retained ductility (65%).

This paper presents a model developed for predicting the mechanical response of inelastic media with heterogeneous microstructure. Particular emphasis is given to the development of microstructural damage along grains. The model is developed within the concepts of continuum mechanics, with special emphasis on the development of internal boundaries in the continuum by utilizing fracture mechanics-based cohesive zone models. In addition, the grains are assumed to be characterized by nonlinear viscoplastic material behavior. Implementation of the model to a finite element computational algorithm is also briefly described, and example solutions are obtained. Finally, homogenization procedures are discussed for obtaining macroscopic damage dependent mechanical constitutive equations that may then be utilized to construct a well-posed boundary value problem for the macroscopically homogenized damage dependent medium.

Rigid polyurethane foams are frequently used as encapsulants to isolate and support thermally sensitive components within weapon systems. When exposed to abnormal thermal environments, such as fire, the polyurethane foam decomposes to form products having a wide distribution of molecular weights and can dominate the overall thermal response of the system. Mechanical response of the decomposing foam, such as thermal expansion under various loading conditions created by gas generation, remains a major unsolved problem. A constitutive model of the reactive foam is needed to describe the coupling between mechanical response and chemical decomposition of foam exposed to environments such as fire. Towards this end, a reactive elastic-plastic constitutive model based on bubble mechanics describing nucleation, decomposition chemistry, and elastic/plastic mechanical behavior of rigid polyurethane foam has been developed. A local force balance, with mass continuity constraints, forms the basis of the constitutive model requiring input of temperature and the fraction of the material converted to gas. This constitutive model provides a stress-strain relationship which is applicable for a broad class of reacting materials such as explosives, propellants, pyrotechnics, and decomposing foams. The model is applied to a block of foam exposed to various thermal fluxes. The model is also applied to a sphere of foam confined in brass. The predicted mechanical deformation of the foam block and sphere are shown to qualitatively agree with experimental observations.

Determination of product species, equations-of-state (EOS) and thermochemical properties of high explosives and pyrotechnics remains a major unsolved problem. Although, empirical EOS models may be calibrated to replicate detonation conditions within experimental variability (5--10%), different states, e.g. expansion, may produce significant discrepancy with data if the basic form of the EOS model is incorrect. A more physically realistic EOS model based on intermolecular potentials, such as the Jacobs Cowperthwaite Zwisler (JCZ3) EOS, is needed to predict detonation states as well as expanded states. Predictive capability for any EOS requires a large species data base composed of a wide variety of elements. Unfortunately, only 20 species have known JCZ3 molecular force constants. Of these 20 species, only 10 have been adequately compared to experimental data such as molecular scattering or shock Hugoniot data. Since data in the strongly repulsive region of the molecular potential is limited, alternative methods must be found to deduce force constants for a larger number of species. The objective of the present study is to determine JCZ3 product species force constants by using a corresponding states theory. Intermolecular potential parameters were obtained for a variety of gas species using a simple corresponding states technique with critical volume and critical temperature. A more complex, four parameter corresponding state method with shape and polarity corrections was also used to obtain intermolecular potential parameters. Both corresponding state methods were used to predict shock Hugoniot data obtained from pure liquids. The simple corresponding state method is shown to give adequate agreement with shock Hugoniot data.